PD501 Monitor Manual-P6381 PDF

THIS IS CONFIDENTIAL INFORMATION.
THIS DRAWING AND DESIGN IS THE PROPERTY OF LIQUIP INTERNATIONAL PTY LIMITED.
IT MUST NOT BE COPIED OR REPRODUCED IN ANY WAY WHATSOEVER AND/OR PASSED ON
TO ANY THIRD PARTY WITHOUT WRITTEN AUTHORITY.
LIQUIP INTERNATIONAL PTY LIMITED - ENGINEERING DEPARTMENT - 13 HUME RD SMITHFIELD SYDNEY NSW AUSTRALIA 2164
PH: +61 2 9725 9000 FAX: +61 2 9609 4739 EMAIL: engineering@liquip-nsw.com.au
LIQUIP INTERNATIONAL PTY LIMITED
QUICK REFERENCE AND

INSTALLATION SUMMARY
AND
INSTALLATION AND
SPECIFICATION MANUAL
FOR
PD501 SERIES OVERFILL AND

GROUND ASSURANCE MONITORS
6381
THE ‘INSTALLATION SUMMARY’ IS TO BE SEPARATED FROM THE

‘INSTALLATION AND SPECIFICATION MANUAL’
PRODUCT-INFO\PDxxx\5-INSTALL-FITTING\PD501_Monitor_Manual- P6381.doc Issue: K 29/8/05 -1-

INFORMATION PERTAINING TO WORKING ON A TANK VEHICLE
1. Prior to working on a tank vehicle it must be degassed or certified to work on. Before
working in a tank compartment an appropriate device must be used to check for the
presence of volatile gases.
2. Any work carried out on a tank vehicle must be done so in a non-hazardous area.
3. Before working on any electrical equipment on a tank vehicle power must be isolated either
via the battery isolation switch (BIS), by disconnecting the truck battery or by disconnecting
the positive of the electrical equipment.
4. Never weld on a tank vehicle unless all electronic equipment is completely disconnected
electrically from both the tanker and other equipment.
5. Hazardous conditions may be present when working with high voltage devices (such as
gantry monitors). Qualified technicians only should be servicing these devices.
6. Do not connect a battery charger or other pulsed power supply to the truck battery without
first isolating all electrical equipment as permanent damage may result.
7. Long sleeve and pants protective clothing should be worn at all times. Clothing must be non-
static generating. Any petroleum contact with skin should be washed off immediately.
8. Always follow manufacturer guidelines when working on electrical equipment. Failure to do
so may void warranty or cause damage.
INFORMATION PERTAINING TO INSTALLING EQUIPMENT ON A TANK VEHICLE
1. All electrical equipment and fittings must be suitable for use on a tanker and meet all local
regulations for operation.
2. Use high quality waterproof conduit and fittings to IP66 minimum for all wiring and junction
boxes.
3. Use waterproof flexible compound such as Silastic in all glands and joints not available as
waterproof by design.
4. Mount all equipment away from direct spray areas such as behind the tyres and out of direct
sunlight. Always select the most sheltered aspect.
5. Ensure all installations adhere to appropriate guidelines.
6. Coat all terminals, cable end and joints with non-conducting grease or Vaseline after final
testing. This will prevent corrosion.
7. Prior to crimping, check wiring connections are electrically correct. When crimping, make
sure there is good electrical contact between the wire strands and metal section of the crimp
terminal. Pull on the crimp to ensure a good connection has been made.
8. Cable ends may be crimped with ferrules for better connection. Do not solder the cable ends
(fatigues and corrodes). Pre-coat with non-conductive grease for corrosion protection.
9. At any point a cable is extended or joined to a standard cable assembly, all cable screens
must be connected to the chassis as well as being joined together at a star point. Insulate
exposed screen wire using heat shrink, terminate with an eye-terminal and attach to the
junction box mounting screw. If the junction box is mounted to a panel not electrically
connected to the chassis, the screens must still be joined together.
10. It is recommended the negative terminal of the battery be connected to the chassis.

11. Common grounding of a system is most important. Do not rely on common chassis
grounding at various points, run a full-length dedicated ground cable. Max resistance, battery
ground to any ground point to be 1Ω. Refer Liquip Tech Talk #48: Electrical Bonding on
Tankers. The electrical resistance between the tank and tanker chassis, prime mover
chassis, or trailer undercarriage, and between the tank and the connection of the tanker
pipework to the delivery hose, shall not exceed 10Ω.
12. Always fit as much loose cable length into junction boxes and housings as practicable to
allow for future servicing.
13. When pulling multiple cables through conduit always consider using cable with one or two
extra conductors to allow for any future requirements.
14. Always completely segregate power and intrinsically safe wires into completely safe conduit
and in accordance with I.S wiring rules.
15. Carry out a complete wiring check for accuracy and continuity before connecting power to
any device.
16. All equipment must be supplied from a fused power supply.
17. Observe international and local legal requirements. In the event of conflicting instructions
seek qualified advice before proceeding.
18. Do not route communication cables past ‘noisy’ electrical apparatus such as solenoids and
alternators.
19. Check instruction manual for recommended cable type and torque settings.
20. Use specialised, genuine tools for all electrical work.
21. Mount equipment to clean, dry, bare surfaces on a metal bracket mounted to the
chassis/sub-frame. It is recommended the bracket be welded to the chassis/sub-frame to
facilitate good electrical contact.
22. Ensure adequate clearance around equipment being installed. This will provide for ease in
future maintenance.
23. When bolting equipment into place, the use of Teflon tape or anti-seize compound on
threads is advised.
24. Prior to welding a socket into a tank or pipe it is advised a pipe plug be inserted before
welding to prevent heat distortion of the socket. An anti-seize lubricant may be used to help
with plug removal.
25. If possible run power wires directly from the equipment being installed to the battery isolation
switch. This will avoid the use of intermediary junction boxes ensuring proper voltage and
grounding.
26. Fuses located in hazardous areas must be suited to that location.
27. Always allow suitable separation (at least 50mm) between intrinsically safe wiring and power
from line power source. Do not mix AC and DC power wiring (maintain barrier separation).

QUICK REFERENCE AND INSTALLATION SUMMARY

POWER WIRING
1. Check the local voltage (240V or 110V), the fuses and lamps and make sure it matches the model
supplied. See item (3), (4) and (2) of schematic drawing on the next page (Drawing No. X951400).
2. Wire up the top terminals of the PD501 main board as shown on the schematic drawing - item (16)
and (17).
3. Ensure mains earth is connected to the “E” terminal ONLY. Item (17) on schematic drawing. Do not
run any separate earth to the housing.
INTRINSICALLY SAFE WIRING

1. Check jumpers JP6 to JP9 to suit your application, as shown in the table below. (Unit should be
preset at factory).
2. Wire up the PD501 lower connector (intrinsically safe terminals) as required. Refer items (9), (10)
and (11) of the schematic drawing on the next page (Drawing No. X951400).
JP7 JP8
REF PD501 CONFIGURATION JP6 JP9 DRAWING No.
(D) (C)
X950997 (For 8-Compt. Tanker)
1. 2-Wire Probe Only ON OFF OFF OFF
2. 5-Wire Probe Only ON OFF OFF OFF X950197
2-Wire And Integral Ground (Diode X950997 (For 8-Compt. Tanker)
3. Check) OFF ON OFF OFF
5-Wire And Integral Ground (Diode
4. OFF ON OFF OFF X950197
Check)
2-Wire And Ground Clamp (Earth X951197 (For 8-Compt. Tanker)
5. Check) OFF OFF ON OFF
5-Wire And Ground Clamp (Earth
6. OFF OFF ON OFF X951397
Check)
2-Wire And Ground Ball (Diode X951097 (For 8-Compt. Tanker)
7. Check) OFF ON OFF OFF
5-Wire And Ground Ball (Diode
8. OFF ON OFF OFF X951297
Check)
9. Ground Integral Only (Diode Check) OFF ON OFF ON Refer to Ref. 3 and 4
10. Ground Clamp Only (Earth Check) OFF OFF ON ON X950797
11. Ground Ball Only (Diode Check) OFF ON OFF ON X950897
“ON” = link (jumper) is connected
“OFF” = link is removed
Cable specifications for Intrinsically Safe installations;

Resistance R = 0.0178 Ω/m
Capacitance C = 45 pF/m
Inductance L = 0.325 µH/m


LIQUIP INTERNATIONAL PTY LIMITED
INSTALLATION AND
SPECIFICATION MANUAL
FOR
PD501 SERIES OVERFILL AND

GROUND ASSURANCE MONITORS
6381
APPLIES TO THE FOLLOWING VARIANTS OF THE PD501 MONITOR
* 5-Wire Overfill Monitor with Integral Ground Assurance
* 2-Wire Overfill Monitor with Integral Ground Assurance
* Ground Assurance, Stand-Alone
* 5-Wire Overfill Monitor with Ground Assurance by Second Cable
* 2-Wire Overfill Monitor with Ground Assurance by Second Cable

INDEX
1 Applications.
2 Configurations and numbering system for ordering.
3 Ground Assurance — Importance of truck-side installation.
4 Description of monitor - general.
5 Installation and wiring of monitor - general.
6 Description of junction box, cable and plugs - general.
7 Installation of junction box, cable and plugs - general.
8 Installation and wiring diagrams for each variant.
8.1 System Settings
8.2 5-Wire overfill protection, stand-alone.
8.3 2-Wire overfill protection, stand-alone.
8.4 Ground assurance, stand-alone. (Socket or clamp connector).
8.5 5-Wire overfill protection with separate ground assurance.
8.6 2-Wire overfill protection with separate ground assurance.
9 Fault-finding.
10 Recommended spare parts.
APPENDICES
A Truck plug installation to ensure grounding of the tank.
B Truck plug with diode for operation with ‘Ground Hog’.
C Monitor dimensions and mounting information.
D Junction box dimensions and mounting details, cables, connectors.

1.0 Applications
1.1 The PD501 Monitor incorporates three main functions:
5-Wire probes overfill protection monitor, catering for up to 15 optical probes of any major
manufacture.
A single channel 2-wire probe overfill monitor for use with any thermistor or optical probe
of any major manufacture.
A ground assurance feature which can be used stand-alone or wired into the gantry plug
system of the overfill protection cabling to the truck.
1.2 5-Wire overfill system is normally used on road tanker fleets which have more than eight
compartments. PD501 can cater for up to 15 compartments.
It is also used on tank farms where one monitor can control up to 15 storage tanks (subject
to total length of cabling being within limits).
1.3 2-Wire single channel feature has application where only single compartment vehicles are
loaded. A typical example is rail-car loading.
It uses exactly the same electronic system as the multi-compartment PD108 Monitor, but
provides a much cheaper alternative.

1.4 Ground assurance monitors are rapidly replacing the old style connecting cables that had
no self-checking feature.
Ground assurance means that the monitor continuously checks that a through-circuit
exists from the gantry to the vehicle and back again, i.e. that the monitor box and the truck
are electrically bonded to the same electrical potential. (Refer Section 3 for more detail on
the correct application of ground assurance devices).
This feature is essential in the petrochemical industry where many products have the
dangerous properties of being both flammable and high static-electricity generators.
Ground assurance is used in the loading or unloading of petroleum road tankers, LPG
tankers, rail cars, ships and aircraft.
As described later, grounding can be achieved in three ways:
(i) By the pins of the overfill protection plug, therefore only one connection need be made to
the tanker.
(ii) By crocodile clamp onto the vehicle body.
(iii) By military-style grounding ball (as used by Scully) incorporating a diode.
1.5 The standard monitor is approved for use in explosive atmospheres and is housed in an
appropriate box.
However, if an application allows, the unit can be supplied in a lightweight housing

(which is much cheaper and lighter).

2.0 Configurations and Numbering System
2.1 While all the configuring of the standard monitor can be done on site by a qualified
electrician, Liquip prefer to receive full usage information to enable factory inspection
and checking in full and supply of appropriate junction boxes, cable and connecting
plugs.
2.2 Order from the following coding.
Monitor only:
PD501 XX XXX
110 = 110v Power Supply

240 = 240v Power Supply
P = Probe Monitoring Only

I = Integral Ground Connection
C = Crocodile Clamp Grounding
B = Ground Ball Grounding
T = 2-Wire Overfill Monitor

F = 5-Wire Overfill Monitor
G = Grounding Monitor

Example
Require a 5-wire overfill monitor with separate ground assurance by means of a

crocodile clamp. Power supply is 110v ac.
Order as PD501-FC-110 (monitor only).
Example
Require a single-channel 2-wire overfill protection monitor with integral ground

assurance and power supply is 240v ac.
Order as PD501-TI-240 (monitor only).
Example
Require a ground assurance monitor, stand-alone, with ground ball connector and for
110v ac power supply.
Order as PD501-GB-110 (monitor only).
2.3 Junction box only.
Order as JB100 - standard with two ports 3/4” NPS
Or JB103 - special order with three ports 3/4“ NPS.
2.4 5-Wire overfill protection system cable and plug assembly (three bayonet) GP103
2.5 2-Wire overfill protection system cable and plug assembly (four bayonet) GP104
2.6 Ground ball plug and cable assembly EAB100
2.7 Crocodile clamp and cable assembly EAC201

3.0 Ground Assurance - The Importance of Truck-Side Connections
3.1 The basis of ground assurance is to ensure that the electrical potential of all
connecting devices and personnel is equal. A spark only occurs when two
approaching bodies have unequal electrical charges. It is therefore essential that the
monitor box be properly grounded to the whole gantry structure: that the truck plug
(overfill plug and/or grounding ball) be properly grounded to the truck tank, chassis
and pipework: and that the connecting plug be monitored throughout for correct
connection between truck and gantry.
3.2 Some ground assurance monitor boxes can be totally insulated from the gantry
structure and still give a permissive signal — they have no internal checks to ground.
Therefore, all they achieve is dissipation of static from the box, not from the gantry and
pipework as a whole.
3.3 On the truck side, it is not unusual for the overfill protection wiring to have no assured
integration into the body of the tank (where the static charges are held). Again, it is
possible for the static to be dissipated only from the truck plug, not from the tank.
It is essential that the common (earth) wire of the probes be ‘forced’ to go through part
of the tank structure to ensure grounding. The Liquip ‘ground boss’ truck plug, TP101
series, provides this by means of its special mounting.
Further detail is available from Liquip head office in Sydney Australia on request. Refer
Appendix A for explanatory diagram.

3.4 Proprietary systems that use diodes (e.g. grounding balls and ground bolts).
3.4.1 Ground assurance by means of the grounding ball on the tanker with ground
ball socket from the monitor (e.g. Scully Ground Hog) is based on the use of a
diode in the ground ball to ensure correct operation. The Liquip ground ball
system is fully compatible, as is the monitor.
It is essential to note that all vehicles loading at such a terminal must have the
ground ball fitted.
3.4.2 Ground assurance integrated with overfill monitor, e.g. Scully Ground Hog Box
connected to Overfill Monitor Box and all connections to truck via overfill
connection plug.
In this case a ‘ground bolt’ is fitted in the truck plug, this also being a diode
device to ensure correct operation. Liquip part TP103-7 is fully compatible, as is
the PD501 Monitor.
It is essential that all trucks loading at such a terminal be fitted with the TP103-7
or ground bolt in order to load. See Appendix B for explanatory diagram.
The Liquip PD501 Monitor is particularly flexible in this regard, as it can be

configured to operate with or without the diode system by means of a simple
jumper link. All we need to know is the particular standard being used in the
country or terminal receiving the equipment.

4.0 Description of Monitor
4.1 It is assumed the user of this manual is already familiar with petrochemical loading and
transport operations, the safety requirements to protect against static electricity and the use
of electronic probes to prevent an overfill when loading.
4.2 The PD501 Monitor is the most flexible safety device yet introduced, providing a variety of
functions in the one box that are variable on-site simply by wiring to appropriate terminal
connections.
It provides 2-wire system overfill protection, 5-wire overfill protection, integrated ground
assurance, stand-alone ground assurance and compatibility with plain or diode systems.
4.3 The PD501 Monitor has on the front of the explosion-proof housing two lights and a two
position padlockable switch. From the bottom cable entries a length of armoured cable
extending to a Liquip Junction Box JB10x is required. From the Junction Box there is 8m of
self-store cable with a Liquip Gantry Plug at the end: or an earth assurance connector: or two
cables having the two connectors one on each.
When the tanker enters the gantry or loading position the PD501 will show a red light
indicating that there is no earth assured connection and there is no signal from the overfill
monitor. The driver removes the gantry plug from the storage position and connects the plug
to the truck plug positioned on the tanker or tank chassis. When the tanker is fitted with a
Liquip ‘ground boss’ truck plug assured grounding is achieved through the truck plug. When
the gantry plug is correctly connected the red light is extinguished and the green light is
illuminated indicating assured grounding and the overfill protection system is confirmed and
the permissive contact is closed allowing loading to commence. The sequence is the same
for stand-alone ground assurance, and if both cables are in use, both must be connected to
achieve permissive.
4.4 The explosion-proof housing dimensions and layout are shown on attached drawing
PD36596 in Appendix C.
Power supply port is to the top, with intrinsically safe port to the bottom. A second port on the
top is normally blanked but can be used for volt-free only signal output from permissive relay
if desired (if power output is required, contact Liquip). A spare port on the bottom is also
blanked. The box is hinged to the left for ease of maintenance. The lid has two lights, red for
non-permissive and green for permissive. It also holds a padlockable switch that allows
system by-pass in emergency, when turn on both lamps light up as a warning.
4.5 The unit has been fully tested and approved for explosive gases to classification IIB and
Zone 1 atmospheres that cover all normal loading and unloading gantries.
If the area of use is a safe area, a cheaper housing may be used to reduce cost (available to
special order only).
Should the terminal be loading multi-compartment tankers with both 2-wire and 5-wire
systems, the PD100 Series Monitor should be used.

5.0 Installation and Wiring - General
Each variant of the monitor is detailed in Section 8. This covers the common requirements
for all versions.
5.1 Ensure all local safety and operational regulations are observed and that locally fitted
equipment matches the safety requirements of the monitor and accessories.
Ensure all personnel are suitably qualified, are in possession of this manual and
understand the requirements.
5.2 While not mandatory, Liquip always recommend the use of the JB100 Junction Box
for mounting of cables, not direct into the monitor. The reason is that the truck
connections are those most commonly damaged (e.g. drive-away or run over) and it
is safer and quicker to repair from the junction box than to repair from the main power
box.
5.3 Mechanical mounting information for the PD501 Series Monitor is on drawing
PD36596 in Appendix C.
Glands are not supplied with the box as conduit types vary. Ensure the glands used
are approved explosion proof types and are threaded 3/4" NPT.
Mount the PD501 Series Monitor where it is clearly visible from the driver loading
position.
Mount the junction box such that the gantry plug will reach all truck plugs. Length of
cable when straightened is 8 metres, but position with regard to how the cable will
hang and for any tripping hazards. Please refer to Appendix D for mechanical
mounting information of junction box JB10x.
Position PD501 Monitor out of direct sunlight and rain for all conditions. (The housing
is approved to IP65 and will withstand occasional hosing to clean.).
5.4 Electrical Preparation
5.4.1 PD501 Series Monitor Power Conduit
The PD501 Series Monitor is supplied standard with four cable entries tapped
3/4” NPS for an Exd gland that can take a SWA cable of size 13 - 15mm OD.
We recommend four cores plus Earth SWA cable. Use two cores plus Earth for
power supply input and the remaining two cores can be used to terminate the
permissive output contact to control valve. Recommended minimum wire size is
1.9mm². Relay contact is rated at 240v 5 amps.

5.4.2 PD501 Series Monitor to Junction Box Conduit
The PD501 Monitor to junction box outlet requires an Exd gland of 3/4" NPT
thread and can terminate a cable of size between 13 to 15mm OD. A 10-core
cable is required to run from the monitor to the junction box. Recommended
minimum wire size of individual core is 1mm² or 32 x 0.2mm.
The junction box is normally supplied with two off 3/4” NPS cable entries to suit
Exd glands and cable 13 - 14mm OD. (M25 conduit to 3/4" NPT adaptors are
supplied to convert to metric conduit.).
When twin-cable systems are being used, a special model JB103 can be
ordered to allow wiring take-off to the second cable and connector, e.g. one
cable with overfill plug, the second cable with earth assurance clamp.
Note the junction boxes should be sited to allow easy connection to the tanker
when in its normal parked position and with regard to minimum interference with
loading arms and escape routes.
5.5 Continuity-check all connections to verify prior to closing off the box and powering up.
Supply is verified by the red lamp being ‘on’. Switch to by-pass and both lights ‘on’.
Return switch to normal operation and plug connections into a tanker or a Liquip
tester to verify by green light ‘on’.
Check overfill probes operation by carrying out physical wet tests (immersion) of all
probes in turn.
Ensure the permissive/non-permissive signal from the monitor is being correctly

received by the terminal automation system or shut-down system.

6.0 Description of Junction Box and Connecting Cables and Plugs - General
6.1 This part of the system is certified intrinsically safe and as such can be worked on
without closing down the gantry. That is why Liquip always recommend the use of a
junction box rather than directly into the monitor.
6.2 Characteristics of these components are detailed in Appendix D with their data
sheets.
6.3 When installing twin cable systems such as overfill with ground clamp, the installer
can use a commercial junction box for the second cable termination or order a
special version of the JB100, model JB103, which has two outlet ports to cater for the
two cables.
6.4 All cables are supplied pre-assembled to the truck connectors and are coiled self-
storing type with a stretched reach of 8 metres long.
Overfill protection cable is heavy weight coloured orange.
Ground assurance cable is medium weight coloured black.
6.5 Overfill protection plug for 2-wire systems (model GP104) has 4-bayonet system.
Overfill protection plug for 5-wire systems (model GP103) has 3-bayonet system,
commonly known as API Optic. Both have 10 pins for commonality, however, only
those nominated are connected. Spare pins have future applications for truck-to-
gantry communications.
Ground ball plug connector is to standard military specification and is compatible with
Scully equivalent.
Grounding crocodile clamp has permanently isolated jaws so permissive is only given
when clamped to minimum 4mm thick metal lug.

7.0 Installation of Junction Box, Cables and Connectors - General
7.1 Having sited the monitor so that the lights are in view of the operator from the normal
loading position, the junction box can be mounted where most convenient for
connection to the tanker. Typically, site it opposite the connector on the tanker when
the latter is in its normal parking position.
7.2 The pre-assembled cables and connectors can be supplied complete with all fittings
to screw directly into the 3/4" NPS port on the junction box. It is strongly
recommended that orders should specify this, as no further installation is required.
Cable glands and fittings are not supplied for the cabling between the monitor and
the junction box as local regulations and availability of components make it preferable
for this to be an on-site supply.
7.3 Refer data sheet page P4776 in Appendix D for bolting details for junction box.

8.0 Installation and Wiring Schematics for Each Variant
8.1 System Settings
The following table lists all the jumper settings for the different variants. The jumper
header pins are located on the left side of the intrinsically safe connector (probe
connector).
REF MODEL JP6 JP7 (D) JP8 (C) JP9
1. PD501-TP 2-WIRE PROBE ONLY ON OFF OFF OFF
2. PD501-FP 5-WIRE PROBE ONLY ON OFF OFF OFF
PD501-TI 2-WIRE AND INTEGRAL

3. OFF ON OFF OFF
GROUND (DIODE CHECK)
PD501-FI 5-WIRE AND INTEGRAL
4. OFF ON OFF OFF
GROUND (DIODE CHECK)
PD501-TC 2-WIRE AND GROUND
5. OFF OFF ON OFF
CLAMP (EARTH CHECK)
PD501-FC 5-WIRE AND GROUND
6. OFF OFF ON OFF
CLAMP (EARTH CHECK)
PD501-TB 2-WIRE AND GROUND
7. OFF ON OFF OFF
BALL (DIODE CHECK)
PD501-FB 5-WIRE AND GROUND
8. OFF ON OFF OFF
BALL (DIODE CHECK)
PD501-GI GROUND INTEGRAL
9. OFF ON OFF ON
ONLY (DIODE CHECK)
PD501-GC GROUND CLAMP ONLY
10. OFF OFF ON ON
(EARTH CHECK)
PD501-GB GROUND BALL ONLY
11. OFF ON OFF ON
(DIODE CHECK)
“ON” = PHYSICAL LINK IS CONNECTED
“OFF” = LINK IS REMOVED
8.2 5-Wire Overfill Protection System with Integral Grounding
Refer to attached drawing X952497 and X950197 for gantry wiring.
Refer also to attached truck plug diagrams in Appendix A and Appendix B. All trucks
must be wired the same way between pin 9 and pin 10 for any ground assurance
system to operate.
Applies to models:
PD501 - FI - 110
PD501 - FI - 240

8.3 2-Wire Overfill Protection System with Integral Grounding
Refer to attached drawings X951897, X950997 and X950697 (for those countries
using only six channels, not eight).
Refer also to attached truck plug diagrams in Appendix A and Appendix B. All trucks
must be wired the same way between pin 9 and pin 10 for any ground assurance
system to operate.
Applies to models:
PD501 - TI - 110
PD501 - TI - 240
8.4 Ground Assurance, Stand-Alone
Wiring is the same, for both the crocodile clamp and the ground ball type.
(Notify Liquip of the model required as the crocodile clamp type has a change in
jumper link internally. However, this has no effect on the external wiring.).
See attached drawings X952097 and X950897 (ground ball) and X951997 and
X950797 (crocodile clamp).
Applies to models:
PD501 - GB - 110
PD501 - GC - 110
PD501 - GB - 240
PD501 - GC - 240
8.5 5-Wire Overfill Protection with Separate Ground Connection
See attached drawings X952297 and X951297 (ground ball) and X952197 and
X951397 (crocodile clamp).
Applies to models: PD501 - FB - 110

PD501 - FC - 110
PD501 - FB - 240
PD501 - FC - 240

8.6 2-Wire Overfill Protection with Separate Ground Connection
For countries with 8-channel systems, see attached drawings X951797 and X951097
(ground ball) and X951797 and X951197 (crocodile clamp).
For countries with 6-channel systems, see attached drawings X951697 and X951597
(ground ball) and X951697 and X951497 (crocodile clamp).
Applies to model:
PD501 - TB - 110
PD501 - TC - 110
PD501 - TB - 240
PD501 - TC - 240



















9.0 Fault-Finding
9.1 Tools and Test Equipment Required for Servicing
9.1.1 Tools
- Good quality (digital) multi-meter.
- Flat blade screwdriver.
- Set of metric Allan key.
- Set of metric sockets.
9.1.2 Test Equipment

- Liquip 5-Wire Portable Handheld Tester HTA503 or
- Liquip 2-Wire portable Handheld Tester HTA204.
9.2 Replacing Indicator Lamps
Turn off the power to the PD501 Monitor from the mains supply. Unscrew the allen head
grub screw on the lens cover then remove the lens cover. To remove the multi-LED, firmly
push it downwards and turn in an anti-clockwise direction. Please refer to Section 10 for
Parts Listing for multi-LEDs. Replace the new multi-LED by reversing the removal
procedure.
9.3 Replacing Fuses
Turn off the power to the PD501 Monitor from the mains supply. Unscrew all 16 x bolts and
open the lid. Unplug the fuse holder off the PCB and replace with recommended fuse rating
ONLY. Setup multi-meter for continuity check and test the suspected fuse(s) before
replacing. Refer to Section 10 for Parts Listing of the Fuses.
9.4 Replacing PCB
Turn off the power to the PD501 Monitor from the mains supply. Unscrew all 16 x bolts and
open the lid. Un-screw the earth eye terminal and un-plug the 8-way connector from the lid.
Please refer to Section 10 for Parts Listing of the PCB. Take note of all cables on both
connectors of the PCB before removing them. Unscrew all 6 mounting screws and replace
PCB, please refer to Section 10 for Parts Listing of PCBs.

SYMPTOM: Overfill Gantry Plug is connected to tanker but RED Lamp stays ON and Non-permissive output to external device.
REF MODEL POSSIBLE CAUSE ACTION COMMENT
1. All Models Fuse(s) blown Replace fuse(s) Refer to Section 9.3 Clean contacts of the fuse holder
2. All Models Faulty probe(s) - Use appropriate Liquip Hand-Tester to prove
probes and Monitor.
5-WireHTA503 or
2-Wire HTA204.
3. - PD501-FI-110/240 - Bad grounding on tanker’s side - Use HTA503 Tester to check for diode on truck - You can check for the diode
5-Wire with integral on grounding bolt in truck plug plug before replacing PCB. between pin 9 and 10 of the truck
Diode/Ground. plug without removing the cover.
- PD501-TI-110/240 Diode should conduct from pin 10 to
2-Wire with integral
9 but not 9 to 10. If short circuit both
Diode/Ground.
ways, diode is missing.
4. - PD501-FC-110/240 - Bad grounding on the crocodile - Check and make sure that the Crocodile Clamp
5-Wire with clamp is biting into clean metal surface of tanker.
Crocodile Clamp - Check open voltage across jaws should be
Grounding 12.9Vdc
- PD501-FC-110/240
2-Wire with
Crocodile Clamp
Grounding
5. - PD501-FB-110/240 - Bad grounding on grounding ball - Check and make sure that the Ground Ball
5-Wire with Ground adaptor’s contacts are clean and making proper
Ball Grounding contact to the tank shell.
- PD501-FB-110/240 - Check open circuit voltage on the gantry socket
2-Wire with Ground (should be 7.0Vac)
Ball Grounding - Use HTA204 or HTA503 to check vehicle
ground & presence of diode.

SYMPTOM: Overfill Gantry Plug is connected to tanker but RED and GREEN Lamps stay OFF but Permissive output to external device. (i.e. ON)
1. All Models - Green indicator lamp(s) blown - Replace multi-LED(s) Refer to Section 9.2
SYMPTOM: BYPASS Switch is ON, RED and GREEN Lamps turns ON but Non-Permissive output to external device.
1. All Models - Fuse(s) Blown - Replace Fuse(s). Refer to Section 9.3
SYMPTOM: BYPASS Switch is ON, RED and GREEN Lamps stays OFF but Permissive output to external device.
1. All Models - Indicator lamp(s) blown - Replace multi-LED(s) Refer to Section 9.2

10.0 Spare Parts Listing
10.1 Monitor 110v
P6941 Multi-LED (red) for pilot light

P6942 Multi-LED (green) for pilot light
P5542 5A Output Relay Fuse
P5075 125mA Mains Fuse
P5539 250mA DC Power Supply Fuse
P5509 Switch
P5548 Main board complete
10.2 Monitor 240v
P6939 Multi-LED (red) for pilot light

P6940 Multi-LED (green) for pilot light
P5542 5A Output Relay Fuse
P5573 63mA Mains Fuse
P5539 250mA DC Power Supply Fuse
P5509 Switch
P5547 Main board complete
10.3 Overfill Protection Plug and Cable, 5-Wire System
GP103 Cable and plug assembly

GP103-3 Plug assembly only
P5115 Cable only
10.4 Overfill Protection Plug and Cable, 2-Wire System
GP104 Cable and plug assembly

GP104-4 Plug assembly only
P5115 Cable only
10.5 Crocodile Clamp Ground Assurance
EAC201 Clamp and cable assembly

P6871 Cable only
10.6 Ground Ball Ground Assurance
EAB100 Ground ball plug and cable assembly

APPENDIX A Liquip ‘Ground Boss’ truck plug installation to ensure grounding of the tank.


APPENDIX B Liquip truck plug with diode for operation in terminals with Scully ‘Ground Hog’.
LIQUIP TRUCK PLUG – TP100 SERIES
DATA SHEET
TITLE: Truck plug for overfill protection with added ground assurance.
PURPOSE: Industry standard 10 pin overfill protection plug interchangeable with others of the same
type. However incorporates no-cost wiring connectors that ensure the tanker is bonded
to the gantry so long as the plug body is correctly mounted. This dissipates static
electricity and prevents sparks due to differences in potential.
OPERATION: TP series provides standard 10 pin connection for tanker system with room for an
electronic dummy should this be required in a 2-wire operation.
All of the above is normal.
Where TP series differs is in the way it ensures good grounding of the tanker to the
gantry and ensures dissipation of static electricity and so eliminates sparks. Hence the
name “Ground Boss”
It has long been a recommended practice to break the number 10 common earth return
and “force” it through the tanker chassis by terminating and bolting the wire through the
chassis at a distance apart to ensure grounding of the tank. However the difficulty in
doing this cheaply and neatly has meant that few tankers used the technique.
“Ground Boss” achieves this at essentially no cost by using the mounting bolts inside
the plug. Internal insulating bushes ensure the only electrical path is via the external
fastener, i.e. those bolted to the tanker: and the number 10 common earth wire is run
from pin 10 to one bolt head and from under the other bolt head out via conduit to the
probes. 9 and 10 are simply looped together if required. Therefore the only way the
tanker can load is by having its tank in good contact with the rack monitor earth.
Caution! The “Ground Boss” truck plug must be bolted to the tanker main structure, not
to a potentially isolated bracket or bolted-on substructure.
SPECIFICATION: 3 and 4 bayonet fixing to industry standard

10 pin as standard.
Conduit ports 1/2” NPT (straight) thread, two options.
Mounting by 2 stainless steel bolts 8mm dia via acetal insulating bushes.
VARIANTS: TP103 - 3 pin bayonet fastening

TP104 - 4 pin bayonet fastening. Use also for 2 pin.
WEIGHT: 1.3kg.
MATERIALS: Aluminium nose-cone, hard anodised.

Stainless steel pins and terminator.
Acetal mounting block.
Aluminium body and cover plate.
PVC cap. Order separately (see below).
ASSOCIATED: 5069Z cap kit.

EQUIPMENT DP250 Dummy for 2-wire system.
LC95 / LC99 and AGP102 / AGP105 probes.
GP10x Series gantry plugs.


APPENDIX C Monitor dimensions and mounting information.
LIQUIP MONITOR FOR OVERFILL AND GROUNDING
DATA SHEET PART N°: PD501 SERIES
TITLE: Multi-purpose monitor. Use for 5-wire probe overfill protection: also use for ground
assurance: also incorporates a single channel for 2-wire probes for railcar filling: or
combination of these.
PURPOSE: A single monitor per gantry now provides overfill protection combined with ground
assurance to offer lowest capital cost with simple and cheap installation wiring.
Compatible with all common probes.
OPERATION: Output from the monitor is a single triple-ganged relay signal to provide a go or no-go
control for operation of the gantry or tank farm. Indication is by red or green lamp and a
lockable by-pass switch is standard. Truck plugs may be standard or optic style.
Ground assurance connector may be via truck plug, or ground ball socket, or ‘crocodile’
clamp.
SPECIFICATION: Explosion proof housing for Class 1 Zone 1, monitoring signals intrinsically safe Class 1
Zone 0. Power supply 240v AC or 110v AC. Output (control) relay triple-ganged for
reliability, normally open, volt-free rated at 5 amp 240v (if power output is required,
contact Liquip). Lockable by-pass switch to enable loading in emergency. Cable
entries 3/4" NPS, adaptors to 25mm conduit thread available. Shutdown response time
0.5 seconds for all fault conditions. All model variants are factory set and tested,
however site changes are easily carried out as it is controlled by wiring changes on
output terminal strip. Therefore only one monitor design is required throughout the
terminal and tank farm. SAA approved to Exd (ia) IIB T6 IP65.
VARIANTS: Simple linkages provide the following variations of the same monitor:
5-wire probe overfill monitor
2-wire probe overfill monitor single channel
Ground assurance monitor with crocodile clamp
Overfill monitor with ground assurance wired through truck plug
Overfill monitor with separate cable (clamp or ball type) for ground assurance
All the above in 110v AC or 240v AC power supply
MOUNTING: See attached diagram.
SERVICE: Self-calibrating, no adjustments required. One solid-state board with plug-connector for
quick site changeover.
MATERIAL OF
CONSTRUCTION: Aluminium housing. Explosion proof polycarbonate lights and switch.
WEIGHT: 8 kg.
ASSOCIATED
EQUIPMENT: See data sheet for accessories for monitors. Includes junction box for intrinsically safe
cabling. Optic and standard gantry plugs and self-store cable. Crocodile clamp and
self-store cable for grounding. Ball socket and self-store cable for grounding.
Overall dimensions shown on the drawing overleaf.




APPENDIX D Junction box, cables and connectors data sheets.

LIQUIP ACCESSORIES FOR OVERFILL MONITOR
JB10x JUNCTION BOX, GP10x SERIES GANTRY PLUG & CABLE
DATA SHEET
TITLE: Junction Box, gantry plug & cable for overfill monitors for loading gantries.
PURPOSE: Connects gantry system to tanker via industry standard 3 or 4 bayonet 10 pin plugs for
intrinsically safe signals.
OPERATION: Designed for use with common industry monitors and vehicles as well as Liquip “Probe
Doctor” PD100 Series. Current European I.P. recommendation is to use 4 pin bayonet,
10 pin connectors with automatic monitor switching between 2-wire and 5-wire.
However Liquip manufacture 3 pin and 4 pin bayonet connectors for all applications.
SPECIFICATION: Connect pattern is 10-pin to industry standard and can cater for up to 8 compartments
with 2-wire probes. The Liquip gantry plug also accommodates 5-wire probes. Cable
entries into monitor housing & junction box are tapped 3/4" NPS. Customer to supply
gantry-side connection to suit local requirement. Gantry plug has M25 conduit gland
connection and junction box is supplied with an adaptor for 3/4” NPT. This allows
interchangeability for spare parts.
Cable specifications for Intrinsically Safe installations;

Resistance R = 0.0178 Ω/m
Capacitance C = 45 pF/m
Inductance L = 0.325 µH/m
FEATURE: All materials are non-static producing.

Junction box includes hanger for cable loop-spring.
Socket is heavily ribbed for better grip and bayonet positions clearly visible by being
mounted on bosses.
VARIANTS: GP103: 3-pin bayonet, Blue, supplied with cable, gland & adaptor.
GP104: 4-pin bayonet, Green, supplied with cable, gland & adaptor.
5115 Self-store coiled cable
Gantry plugs are available as spare part, order as GP103-3 or GP104-4.
WEIGHT: 4kg for total including junction box.
MOUNTING: Junction box has two internal mounting holes for 8mm diameter bolts.
MATERIALS: Aluminium box.

Polyurethane plug body.
Stainless steel pins and fittings.
10 core cable, outer polyurethane.
ASSOCIATED: PD100 Series “Probe Doctor” overfill monitor.

EQUIPMENT TP Series “Ground Boss” truck plug.



Earth Assurance Clamp

DATA SHEET PART N°: EAC201
TITLE: Earth assurance clamp EAC201.
PURPOSE: To ensure correct grounding of single channel monitor to truck

chassis.
OPERATION: Before connecting any other equipment to truck, attach clamp to a

suitable grounding point no more than 13mm (1/2") thick.
DISMANTLE: Not recommended
ADJUSTMENT: None required
MATERIALS; Clamp body - cast aluminium

Cable - polyurethane sheathed
Contacts - cone point grub screws – hardened steel
WEIGHT: Clamp & cable 1.3kg
TECHNICAL DATA: 8m cable length supplied
ASSOCIATED EQUIPMENT: PD501 single channel monitor


PD501 Monitor Manual-P6381 PDF

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THIS IS CONFIDENTIAL INFORMATION.

LIQUIP INTERNATIONAL PTY LIMITED

QUICK REFERENCE AND

PD501 SERIES OVERFILL AND

THE ‘INSTALLATION SUMMARY’ IS TO BE SEPARATED FROM THE

PRODUCT-INFO\PDxxx\5-INSTALL-FITTING\PD501_Monitor_Manual- P6381.doc Issue: K 29/8/05 -1-

INFORMATION PERTAINING TO WORKING ON A TANK VEHICLE

INFORMATION PERTAINING TO INSTALLING EQUIPMENT ON A TANK VEHICLE

PRODUCT-INFO\PDxxx\5-INSTALL-FITTING\PD501_Monitor_Manual- P6381.doc Issue: K 29/8/05 -2-

PRODUCT-INFO\PDxxx\5-INSTALL-FITTING\PD501_Monitor_Manual- P6381.doc Issue: K 29/8/05 -3-

QUICK REFERENCE AND INSTALLATION SUMMARY

INTRINSICALLY SAFE WIRING

Cable specifications for Intrinsically Safe installations;

PRODUCT-INFO\PDxxx\5-INSTALL-FITTING\PD501_Monitor_Manual- P6381.doc Issue: K 29/8/05 -4-

PRODUCT-INFO\PDxxx\5-INSTALL-FITTING\PD501_Monitor_Manual- P6381.doc Issue: K 29/8/05 -5-

LIQUIP INTERNATIONAL PTY LIMITED

PD501 SERIES OVERFILL AND

* 5-Wire Overfill Monitor with Integral Ground Assurance

* 2-Wire Overfill Monitor with Integral Ground Assurance

* Ground Assurance, Stand-Alone

* 5-Wire Overfill Monitor with Ground Assurance by Second Cable

* 2-Wire Overfill Monitor with Ground Assurance by Second Cable

PRODUCT-INFO\PDxxx\5-INSTALL-FITTING\PD501_Monitor_Manual- P6381.doc Issue: K 29/8/05 -6-

2 Configurations and numbering system for ordering.

3 Ground Assurance — Importance of truck-side installation.

4 Description of monitor - general.

5 Installation and wiring of monitor - general.

6 Description of junction box, cable and plugs - general.

7 Installation of junction box, cable and plugs - general.

8 Installation and wiring diagrams for each variant.

8.1 System Settings

8.2 5-Wire overfill protection, stand-alone.

8.3 2-Wire overfill protection, stand-alone.

8.4 Ground assurance, stand-alone. (Socket or clamp connector).

8.5 5-Wire overfill protection with separate ground assurance.

8.6 2-Wire overfill protection with separate ground assurance.

10 Recommended spare parts.

A Truck plug installation to ensure grounding of the tank.

B Truck plug with diode for operation with ‘Ground Hog’.

C Monitor dimensions and mounting information.

D Junction box dimensions and mounting details, cables, connectors.

PRODUCT-INFO\PDxxx\5-INSTALL-FITTING\PD501_Monitor_Manual- P6381.doc Issue: K 29/8/05 -7-

1.1 The PD501 Monitor incorporates three main functions:

PRODUCT-INFO\PDxxx\5-INSTALL-FITTING\PD501_Monitor_Manual- P6381.doc Issue: K 29/8/05 -8-

As described later, grounding can be achieved in three ways:

(ii) By crocodile clamp onto the vehicle body.

(iii) By military-style grounding ball (as used by Scully) incorporating a diode.

However, if an application allows, the unit can be supplied in a lightweight housing

PRODUCT-INFO\PDxxx\5-INSTALL-FITTING\PD501_Monitor_Manual- P6381.doc Issue: K 29/8/05 -9-

2.0 Configurations and Numbering System

2.2 Order from the following coding.

110 = 110v Power Supply

P = Probe Monitoring Only

T = 2-Wire Overfill Monitor

PRODUCT-INFO\PDxxx\5-INSTALL-FITTING\PD501_Monitor_Manual- P6381.doc Issue: K 29/8/05 -10-

Require a 5-wire overfill monitor with separate ground assurance by means of a

Order as PD501-FC-110 (monitor only).

Require a single-channel 2-wire overfill protection monitor with integral ground

Order as PD501-TI-240 (monitor only).

Order as PD501-GB-110 (monitor only).

2.3 Junction box only.

Order as JB100 - standard with two ports 3/4” NPS